Stepped combination apparatus

ABSTRACT

A stepped combination apparatus comprises transferring means for moving a bundle of component wires arranged in plural rows and plural lines in the longitudinal direction; pushing means for pushing the component wires to the line direction to put out a component wire at the opposite side; shifting means for shifting the component wire which is put out by the pushing means, to the other row; and stepped-bending means for stepped-bending the component wire which is put out. The operation time can be significantly shortened and a U-shape bundle of component wires can be treated by the apparatus.

This is a continuation, of application Ser. No. 962,992, filed Nov. 22,1978 now U.S. Pat. No. 4,304,033.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a machine tool which automaticallycarry out rebel shifts of stator winding of an AC machine.

2. Disclosure of the Prior Arts

It has been well-known that the stator winding of a large sizesynchronous machine is prepared by twisting many component wires(insulated rectangular type wires) as rebel shifting, in order toprevent a loss caused by eddy current. In many cases, the shape of thestator winding is in a diamond coil shape and the insulated diamond coilis put in each open slot of the stator.

It has been usual to rebel-shift a bundle of component wires by a handoperation or by using a machine tool for twisting component wires byturning slowly a disc holding a drum of the component wires while takingout the component wires.

In the latter case using the machine tool, the stepping of the componentwires is carried out for each pitch by pressing the component wires.

Referring to the drawings, the conventional stepping operation will beillustrated.

In the drawings, the same references designate identical orcorresponding parts and a hatch for a sectional view is eliminated so asto be easily understood in certain drawings.

FIG. 1 shows a bundle of component wires treated by the rebel shiftingand FIG. 1(a) is a sectional view perpendicular to the component wiresand FIG. 1(b) is a sectional view parallel to the component wires. Thereference numeral (100) designates a bundle of component wires which arearranged in two rows extending in a row direction and several linesextending in a line direction; (200) designates an insulator between tworows and (300) designates an insulator for a shifted wire (hereinafterreferring to a S-insulator). As shown in FIG. 1(b), the component wireof the bundle (100) is shifted from the lower row to the upper row andthe other component wire is shifted from the upper row to the lower row(the latter is not shown in FIG. 1(b)). The shifting point of theadjacent component wire is departed for one pitch shown as P in FIG.1(b). The component wire is also shifted in the lines at the shiftingpoint for the row whereby the component wires of the bundle arealternatively shifted.

In order to prepare such structure of the bundle of component wires by ahand operation, it is necessary to carry out the stepping of thecomponent wires first.

FIG. 2 is a side view of a part of the stepped component wires. Thestepped height W is equal to the sum of the width of the component wireand an insulator (200) between the rows and the distance between theshifting points of the adjacent component wires is one pitch P which isusually 50 mm to 100 mm.

When number of the lines of the component wires is N and, thestepped-bending of the component wires is carried out the component wireshifted is returned to the original condition at the distance departedfor NP from the shifted point. Thus, the shaped component wires for onerow are disposed on a table so that the edges are upper and the centralparts are lower. The edge of the component wire which has the longestnon-contacting portions, is lifted up and is crossed over the other bentcomponent wires and is put on the opposite side. Then, the adjacentcomponent wire is moved in the same manner in sequence. After finishingedges of the component wires in one side, the edges of the componentwires in the other side are moved in the same manner from the longestnon-contacted component wire in sequence.

In the operation, the non-contacted parts which should be lifted aresometimes about 4 m and the component wires are thin and easily bent.Accordingly, sometimes, it is necessary to lift up the component wire bythree to four persons. The hand operation is simple but requires thelabour work by many persons.

The other component wires in the other row are combined in the samemanner. The former grouped component wires are turned over to cover onthe latter grouped component wires and the edges of non-contacted partsof the latter grouped component wires are shifted on the contactedportion of the component wires. The other edges of the grouped componentwires are also shifted in the same manner. The insulator between therows (200) is inserted after the shifting operation. The hand operationis quite complicated as described. Moreover, in the operation, it isnecessary to treat the component wires by stepped bending. The componentwires for each row are previously combined and then, the two groupedcomponent wires for two rows are further combined. Accordingly, it isevident for a hand operation that the rebel shifting can be attainedonly for a simple half coil prepared by carrying out the steppedcombination for straight portions of the component wires and thenbending the coil ends to curve them. Thus, the curved bundle ofcomponent wires or the bundle of component wires whose one ends arefixed such as one turn full coil or the coil ends could not be treatedby the rebel shifting.

The half coil is prepared by cutting off both of noses of the diamondcoil.

The one turn full coil is prepared by cutting off one end of the nose ofthe diamond coil. The rebel shifting is performed in the slot part.

The coil end means the part having relatively slight curve from thestraight part of the slot part to the nose part.

The conventional machine disposing many drums of the component wires ona disc table has been used for a small number of the component wires inone bundle.

When the number of the component wires are 40 to 150 as a stator coil ofa rotary machine, the number of the drums of the component wires isgreat. Accordingly, such machine has not been used in the field of coilsof rotary machines.

The disadvantages of the conventional methods are as follows.

(a) it is operation requiring many steps and greater labour costs

(b) the stepped combination could be attained only for straightcomponent wires; and

(c) it is necessary to combine an insulator between rows.

The operation for inserting the insulator for shifted wire (6) iscarried out after the stepping operation. That is, the component wiresare bent and shifted, a spatula having a thin edge of a width of 10 mmand a thickness of 5 mm is inserted into a gap under the component wire(10) which has been bent and shifted and an insulator for shifted wire(6) having a predetermined size is inserted into the space. Theinsulator for shifted wire (6) is a sheet having a thickness of 0.1 to0.2 mm on which mica is bonded.

It takes about 10 seconds to shift one part and accordingly, it takesabout 30 to 60 minutes for one coil.

Thus, the stepped combination is a simple work but it requires a longlabour time and many persons to be low productivity, disadvantageously.

SUMMARY OF THE INVENTION

It is an object of the present invention to overcome the above-mentioneddisadvantages and to provide an apparatus for automatically carrying outthe stepped combination without a hand operation to improve theproductivity and to reduce the labour work.

It is another object of the present invention to provide an apparatuswhich overcomes a complicated hand operation and provides advantagesthat rebel shiftings can be applied to a coil end or a straight part ofa one turn full coil because the bendings of component wires for fixingone end or one part of a bundle of component wires can be applied beforea stepped combination.

It is the other object of the present invention to provide an apparatusfor continuously preparing U-shaped bundle of component wire by ashuttle winding in rebel shifting for a one turn full coil.

It is the other object of the present invention to prevent assemblyduring or after a stepped combination since an insulator between rowsand a thin pipe for cooling can be arranged before the steppedcombination.

In accordance with the apparatus of the present invention, a wide floorarea is not required and the rebel shifting and the insertion of aninsulator for shifted wire can be easily attained for a short time by asimple apparatus.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a windings formed by a rebel shifting; and FIG. 1(a) is asectional view perpendicular to the component wires and FIG. 1(b) is asectional view parallel to the component wires;

FIG. 2 is a side view of stepped component wires;

FIG. 3 is a schematic view of an important part of one embodiment of theapparatus of the present invention;

FIGS. 4, 5, 6, 7, 8 and 9 respectively show the operations according tothe present invention; and FIGS. 4(a), 6(a) and 7(a) are respectivelyfront views thereof; and FIGS. 4(b), (c) FIGS. 5(a), (b), FIGS. 6(b),(c), FIGS. 7(b), (c) and FIGS. 8(a), (b) are respectively side viewsthereof; and FIG. 9 is a plan view;

FIG. 10 is a sectional view of a thin metal tube for passing air;

FIG. 11 is a schematic view of the other embodiment of the presentinvention;

FIG. 12 shows detail of rollers;

FIG. 13 shows steps for stepped combinations;

FIGS. 14 and 15 are respectively a side view and a plan view of theother embodiment of the present invention;

FIGS. 16 and 17 respectively show presses and dies used for bending inthe present invention;

FIGS. 18(a), (b) are a side view and a front view of an apparatus forclamping insulators under a shifted wire;

FIG. 19(a), (b), (c) are respectively a plan view, a side view and afront view for showing a transferring device for transferring a bundleof component wires and a knife device for cutting a lower part of theinsulator under a shifted wire;

FIGS. 20(a), (b) are sectional views and side views for illustratingsteps given by the apparatus of the present invention; and

FIG. 21 are sectional views for illustrating a component wire recyclingdevice.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIG. 3 is a schematic view of the important part of one embodiment ofthe apparatus of the present invention. In FIG. 3, the extended parts ofthe component wires (100) in the directions of X, X' and Y, Y' are notshown and can be a cut edge or the edges in X and X' directions can beconnected through a nose. The shape of connecting the edges is called aone turn full coil shape.

In FIG. 3, the references (1a), (1b) form a component wire bendingdevice. In the embodiment of FIG. 3, the bending device has a pressmechanism having the upper mold (1a) and the lower mold (1b). Thebending device can include other mechanisms such as a roller mechanismand a lever mechanism beside the press mechanism.

The reference (2a) designates a knife device for separating a componentwire for stepped combination from the adjacent component wire; (2b)designates a push rod which pushes the component wires for steppedcombination to shift one step; (2c) designates a hook device forchanging the row of the component wire for stepped combination.

The apparatus of the present invention has a structure comprising aposition shifting device and a drive controlling device (not shown)wherein the position shifting device fits and transfers the bundle ofcomponent wires (100) to a predetermined position depending upon thepredetermined program and shifts the parts for stepped combination insequence to the position shown in FIG. 3 and transfers the bundle ofcomponent wire (100) for one pitch P to X, X' direction after eachstepped combination of said part, and carrying out the next steppedcombination at the position departed for one pitch P; and the drivecontrolling device drives the knife device (2a), the push rod (2b), thehook device (2c) and the component wire bending device (1a, 1b)depending upon a predetermined program.

These devices are not shown in FIG. 3 since a design of these devicesare well-known by a person skilled in the art. (One embodiment of thesedevices is shown in FIG. 19.)

The operation of the apparatus of the present invention will beillustrated.

For example, a preparation of the component wires in the first step inthe case of a manufacture of a diamond coil, is carried out in theseparate place, by a hand operation or a shuttle winding operation.

In the shuttle winding operation, a length of a spool is about 1/2 ofthe expanded wire of the diamond coil and a width of the spool is thesame with the inner diameter of the nose of the coil and a width of thegroove of the spool is two times of the width of the component wire. Twocomponent wires are wound on the spool in parallel for number of turnscorresponding to the required stepped combinations. Then, the spool isdisassembled to remove the bundle of component wires and the bundle isbound by a string if necessary to prevent a break of the bundle. Acenter of the nose at one side is cut by a large clipper and the curvedportions are straighten by a wooden hammer.

Usually, the rebel shifting is performed only at the slot part of thediamond coil and accordingly, each insulator (200) is inserted into eachrow at the slot parts. The insulator (200) can be a polyamide resinsheet (5 mils) such as Normex 411 (manufactured by DuPont).

The operation of the apparatus of the present invention will beillustrated referring to FIGS. 4, 5, 6, 7, 8 and 9 wherein FIGS. 4(a),6(a) and 7(a) are respectively front views; FIGS. 4(b), (c), 5(a), (b),6(b), (c), 7(b), (c) and 8(a), (b) are respectively side views and FIG.9 is a plan view.

In the step of transferring the bundle of the component wires (100), therelation of the component wires (100) and the devices (1a), (1b), (2a),(2b) and (2c) are shown in FIG. 4. FIG. 4(b) is a side view taken fromthe A-A' plane of FIG. 4(a) in the arrow direction; FIG. 4(c) is a sideview taken from the B-B' plane of FIG. 4(a) in the arrow direction.

In FIG. 4(c), the reference numbers (3) to (14) are given for thecomponent wires (100) and the stepped combination is given for thecomponent wire (8) and the component wire (14). The component wire (8)is shifted to the lower row and the component wire (14) is shifted tothe upper row. The shifting is carried out in the following order. Thecomponent wire is referred to as a wire. As shown in FIG. 5(a), theknife devices (2a) are respectively inserted between the wires (8), (7)and between the wires (14), (13) whereby the wires (8), (14) are free toshift and to be inserted between the press molds of the component wirebending device (1a), (1b) in a precise manner. At this time, the hookdevices (2c) are pushed to the center by springs whereby the hookdevices are outwardly shifted and prevent a falling of the wires (8),(14).

Then, the push rods (2b) are pulled as shown in FIG. 5(b). The bundle ofthe component wires (100) is held by the knife device (2a) to preventbreaking.

In the next step, the wires are pressed by the component wire bendingdevice (1a,1b) to form a step as shown in FIGS. 6(a), (b) andsimultaneously, the wires stepped by the pressing are respectivelyshifted (the wire (8) is downwardly shifted and the wire (14) isupwardly shifted).

In the returning step shown in FIGS. 7(a), (b), (c), the push rods (2b)are returned to push the wires (8), (14) while hook device (2c) arereturned and the press molds (1a, 1b) are vertically returned and theknife devices (2a) are pulled out.

In the next step shown in FIGS. 8 and 9, the pushing force of the pushrods (2b) is increased to push the wires (8), (14) into the row wherebythe wires (13), (7) are pushed out. The stepped combination for onepitch is finished. The condition is now returned to the condition shownin FIGS. 4(a), (b), (c) except the wire (7) is shifted to the positionof the wire (8) and the wire (13) is shifted to the position of the wire(14).

The bundle of the component wires (100) is transferred for one pitch andthe next stepped combination is carried out.

As it is clearly understood by the above-mentioned description, it isunnecessary to form a stepped shape before the bounding of the componentwires as the conventional method.

In the present invention, the bundle of component wires are previouslyprepared and one end of the bundle is fixed and then, the steppedcombination can be carried out in sequence from the other end. Thus, thefollowing preparation can be attained.

The conventional stepped combinations are applied on the straight partof a half coil, and then, the end of the straight part is bent and then,the stepped combinations of the coil end part are applied from the endof the straight part to the coil end in sequence by the apparatus of thepresent invention. Of course, the stepped combinations at the slot partas the half coil can be carried out in the straight part of the bundleof component wires.

In the embodiment of the present invention, the insulator is insertedbetween the rows of the wires. Thus, it is also possible to insert theinsulator after the stepped combinations without inserting each step. Inthe case of a large size coil a, thin metal tube for air cooling isarranged in the row of the component wires and the stepped combinationsare carried out, whereby the bundle of component wires incorporating thetube (400) in the rows shown in FIG. 10 can be obtained.

In FIG. 11, the reference numerals (1-1), (1-2) designate rollers whichare disposed as pairs at both sides of the bundle of component wires(30) of a formerly wound coil and in each interval of 30 to 50 cm in thelongitudinal direction of the bundle (30). The reference numeral (2)designates a press type or lever type stepping mechanism for bending thewire (10) to form the stepped shape and (3) designates a transferringmechanism to transfer the bundle of component wires (100) to the arrowdirection finishing each time finishing one step operation is finished,to the position under the stepping mechanism (2) for the next steppingoperation. The stepped combination device is formed with the rollers(1-1), (1-2), the stepping mechanism (2) and the transferring mechanism(3).

The rollers (1-1), (1-2) will be illustrated in detail.

The rollers (1-1), (1-2) are the same as each other.

Referring to FIG. 12, the roller (1-1) is illustrated. FIG. 12 (4-1) isa plan view; (4-2) is a front view and (4-3) is a right side view; (4-4)is an expansion view for showing the shape of the surface of the roller(1-1).

On the surface of the roller (1-1), a groove having a width largerslightly than the width of one component wire (10) is formed so as toshift the component wire (10) for a length of the sectional view of thecomponent wire (10) in the longitudinal direction during one turn of theroller (1-1) (between a to b in one turn). There is no groove in the artc . The distance from the center of the roller (1-1) is an average ofthe distance from the center to the bottom of the groove and thedistance from the center to the surface of the roller (1-1) having nogroove (between a and b ).

The groove is smoothly changed from c to a and b to c .

The rollers (1-1), (1-2)) having said structure are turned in thepredetermined relation to the stepping mechanism (2) and thetransferring mechanism (3).

The operation will be illustrated. The component wires are arranged intwo rows between the rollers (1-1), (1-2) under the condition that thewires are contacted with the non-groove parts of the rollers (1-1),(1-2) (the part c in FIG. 12) and the stepped condition (5-1) in FIG.13.

In the arrangement, the rollers (1-1), (1-2) are turned to the arrowdirection shown in FIG. 13 (13-1), whereby the wires (10) in the upperrow are shifted to right and the wire (10) in the lower row are shiftedto left whereby each wire is put in each groove of the rollers (1-1),(1-2) as the step (5-2) of FIG. 13. Then, each wire in each groove istransferred by turning the rollers (1-1), (1-2). The wire (10) No. 12 inthe right roller (1-2) of FIG. 13 is shifted downwardly whereas the wire(10) No. 15 in the left roller (1-1) is shifted upwardly. Thiscorresponds to the steps (13-2), (13-3), (13-4) in FIG. 13.

The stepping mechanism is simultaneously operated together with theoperation whereby the wires (10) No. 12 and No. 15 are bent and then,the transferring device (3) is operated to transfer the bundle ofcomponent wires (30) so as to conform the position for stepping to thestepping mechanism (2). Then, the wires are shifted and they arereturned to the first step (13-1).

The operations are shown in Table 1 wherein the symbol * designates thestructure shown in FIG. 11; ** designates the position contacting therollers with the component wires (the surface in FIG. 12); and ***designates the step shown in FIG. 13.

                  TABLE 1                                                         ______________________________________                                                 Functional part in                                                            operation (element)                                                                                       *Trans-                                                               *Step-  fer-                                                                  ping    ring                                     Step       *Roller           mech.   mech.                                    ______________________________________                                        1. Shifting to step                                                                      o     **                                                            direction       ○b  →  a○                                                ○a  →  b○                                                ***         (13-5)                                                                        (13-1)                                                                        (13-2)                                           2. Shifting to row                                                                       o     **                o                                           direction       ○a  →  b○                                Stepped bend-   ○b  →  a○                                ing             ***         (13-3)                                                                        (13-4)                                           3. Transferring to                                                                             **                      o                                     wire direction  ○b                                                                     ○a                                                                     ***         (13-4)                                           ______________________________________                                    

In the embodiment, the rollers (1-1), (1-2) are arranged so that thegrooves are in a horizontal direction as shown in FIG. 14. Thus, therollers can be arranged in slant. In this case, the grooves of therollers (1-1), (1-2) are in parallel to the rows of the wires (10)whereby the insulation coating for the wires (10) is not damaged.

The rollers (1-1), (1-2) are not limited to ones having the function forone pitch in one turn and they can be ones having the function for onepitch in one of several turn as shown in FIG. 15.

Referring to FIGS. 16 and 17, the die (21) and the press (22) of thestepping mechanism (20) for stepped-bending the wire (10) will beillustrated in detail.

Grooves (21a), (22a) are formed on the die (21) and the press (22) so asto carry out the stepped-bending of the wire (10) under the condition ofcontacting short sides of the wires in the sectional view.

The parts f , g are in the shape of knife edge and the part e is agroove having a depth of about 0.5 mm.

Referring to FIGS. 18(a), (b) as the side view and the front view, theinsulator inserting device (30) which inserts an insulator (6) under ashifted wire (S-insulator) during the shifting step will be illustrated.

The S-insulator (6) is cut in suitable width and it is wound on a coiler(31). Rollers (32) intermittently turn to transfer the S-insulator (6)to the arrow direction and a guide (33) leads the S-insulator (6) to apredetermined position.

Referring to FIGS. 19(a), (b), (c), a transferring device (40) fortransferring the bundle of component wires (100) for one pitch and theknife device (50) for cutting the lower part of the S-insulator (6) willbe illustrated.

The transferring device (40) is disposed on both sides of the bundle ofcomponent wires (100) and supporting rods (41) can be shifted in thetransversal direction and a shoe (42) is connected on the supportingrods (41) by pins (43).

When the supporting rods are shifted to the right in FIG. 19, the shoe(42) is shifted to the arrow direction whereby the shoe (42) slides onthe bundle of component wires (100). Thus, when the rods are shifted toleft, the shoe (42) is crotched to the bundle of component wires (100)by applying the force to the reverse direction to the arrow direction inthe relation of the pin (43) whereby the bundle of component wires (100)is shifted to left.

The knife device (50) is disposed at both sides of the lower surface ofthe bundle of component wires (100) and the knife device (50) is mountedon the rods (41) and is shifted with the rods (41) in the transversaldirection.

The knife edge is disposed so as to contact with the part of theS-insulator (6) contacting with the bundle of component wires (100)whereby the S-insulator (6) is cut during the shifting step when theknife device is shifted to right.

The total operation will be further illustrated wherein the operationsof the mechanisms are illustrated referring to FIGS. 20 (A), (B) and therelation of rollers (1-1), (1-2) and the wire (10) of the bundle ofcomponent wire (100) at the roller part will be illustrated referring toFIG. 21.

In FIGS. 20 and 21, the symbols #1 to #6 designate step numbers. InFIGS. 20 (A), (B), the figures (a) are front views and the figures (b)are plan views and the figures (c) are sectional views in the steps.

FIGS. 21 are sectional views of the bundle of component wires (100)showing the relations of the wire (10) and the rollers (1-1), (1-2).

In FIGS. 20 and 21, the positions of the wires (10) are defined bynumbers of the wires.

The steps will be illustrated.

The wires (10) are arranged in two rows and the S-insulator (6) isinserted between the rows before insulating the bundle of componentwires on the apparatus.

The insulator (6) is a polyamide sheet (5 mil) and the width of theinsulator is slightly narrower than the width of the bundle of componentwires (100).

The rollers (1-1), (1-2) are turned to the position a of FIG. 12. Inthis condition, the wires (10) #11 and #14 are pushed by the rollers(1-1), (1-2) whereby the wires (10) #15 and #12 are respectively put inthe grooves (21a), (22a) of the rollers. The dies (1a) fall near themiddle part between the rows (Step I).

Then, the dies (1a) push the wires (10) #11 and #14 of the bundle ofcomponent wires (100) whereby the wires (10) #12 and #15 arerespectively put out to the opposite sides (Step II).

Then, the rollers (1-1), (1-2) are turned to shift upwardly the wire #12and to shift downwardly the wire #15. The grooves (21a), (22a) of therollers (1-1), (1-2) have slightly deeper depth after the point b ,whereby the wires (10) are vertically shiftable. The dies (1a) and thepresses (1b) are shifted so as to nip the wires #12 and #15. The edges fand g of the presses (1b) and the dies (1a) are inserted into theboundaries of the wires to enlarge the gaps and the positions of thewires #12 and #15 are slightly shifted as shown in the plan view (b)(#3).

When the presses (1b) and the dies (1b) are pressed to finish thestepped-bending of the wires #12 and #15 to give desired shapes, therollers (1-1), (1-2) are stopped at the position c . (Step 3 I)

The rollers (32), (32) are turned to transfer the insulator (6) duringthe shifting and the S-insulator (6) is lead by the guide (33) to thegap between the wires #13, #14 and the presses (1b) and the dies (1a),that is the grooves e formed on the presses (1b) and the dies (1a). Whenthe S-insulator (6) reaches to the upper part of the bundle of componentwires (100), the rollers (32) (32) are stopped to stop the S-insulator(6). (Step II)

Then, the presses (1b) and the dies (1a) are turned to the originalpositions. (Step 4)

The rollers (1-1), (1-2) are turned to stop at the position d . Thewires (10) #12 and #15 at the rollers (1-1), (1-2) are put out from thegrooves (21a), (22a). The wires (10) #13 and #16 are in the same levelwith the wires (10) #13 and #16 because the positions of the surfaces ofthe rollers (1-1), (1-2) are lower level. Thus, the wire (10) #12 and#15 is compressed to the direction of the bundle of component wires(100) whereby the S-insulator (6) inserted below the wires (10) #12 and#15 are firmly fixed. (Step 5 I)

Then, the knife device (50) is shifted in the transversal direction andthe insulator (6) is cut at the projected position below the bundle ofcomponent wires (100). The transferring device (40) is moved to rightand the shoe (42) moves to the arrow direction by the pin (43) wherebythe bundle of component wires (100) is not moved. (Step 5 II)

Then, the transferring device (40) is moved to left and the shoe (42) ispressed to the direction of the wire (10) by the pin (43) whereby thebundle of component wires (100) is moved to left. The movement isstopped at the position moved for one pitch . (Step 6)

The rollers (1-1), (1-2) are turned to the position a and the wires (10)#13 and #16 are put in the grooves (21a), (22a) of the rollers (1-1),(1-2).

The stepped combination for one pitch and the insulator insertingoperation are completed.

In said embodiment, the bundle of component wires (100) is prepared byarranging the wires (10) while plying the wires. It is also possible toprepare the bundle of component wires (100) by the other methods. Forexample, a shuttle winding is prepared as the prepartion of a diamondcoil and the nose at one end is cut to form U-shape and the bundle inU-shape is installated on the apparatus and the stepping of the straightparts of the bundle can be carried out by the method of the presentinvention. It is also possible to carry out the stepping of the straightpart of the half coil (both noses of the diamond coil are cut) and then,to carry out the bending of the edge of the straight part and then, tocarry out the stepping of the coil end (a middle part between a straightpart and a nose part).

In said embodiment, the S-insulator (6) is fed from a roll. However, itis possible to cut the S-insulator (6) for each one length and to feedautomatically each S-insulator (6) to the connecting point.

In said embodiment, the grooves for feeding the S-insulator are (6) atthe rear side of the presses (1b) and the dies (1a). However, in orderto feed the S-insulator (6) in precise manner, holes for passing theS-insulator (6) can be formed in the presses (1b) and the dies (1a). Asthe simple method, it is possible to form a space by departing thepresses (1b) and the dies (1a) from the bundle of component wires (100)while clamping the wires (10) by the presses (1b) and the dies (1a).

In order to carry out the stepped-bending of the wires (10), the presses(1b) and the dies (1a) are used in said embodiment. However, it ispossible to carry out the stepped-bending of the wires (10) by usinglevers. In said embodiment, the rollers (1-1), (1-2) having the slantgrooves (21a), (22a) are used as the device for recycling the wires(10). However, it is possible to use the hooks, the push rods and theknife device.

In said embodiment, the insulator (6) is inserted just after thestepped-bending of the wires. However, it is possible to insert theS-insulator (6) by pushing a spatula between the wires (10) behindseveral pitches from the stepping mechanism to form each space.

These features are covered by the present invention since the untreatedwires (10) of the bundle of component wires (100) are recycled in thestepped-bending operation for one pitch and the S-insulator (6) isinserted for each pitch.

What is claimed is:
 1. A stepped combination apparatus whichcomprises:transferring means for moving a bundle of flat rectangularcomponent wires arranged in plural rows and plural lines in thelongitudinal direction; pushing means adapted to contact one side ofsaid bundle for pushing component wires in the line direction so as tooffset a component wire at the opposite side; shifting means forshifting the offset component wire to another row; stepped-bending meansfor step-bending the component wire which is offset; a knife device forseparating the component wire treating by step-bending and the adjacentwire; rollers, each having a groove on the peripheral surface, each saidgroove having a width for fitting a component wire, said groove beingformed in a slant direction so as to move the wire for the width of saidgroove in a predetermined direction as the wire is passed in said groovedefined in the surface of said rollers during each turn thereof, each ofsaid rollers having a inlet portion connected to each of said grooves,each of said inlets being parallel to the circumference of the roller.2. An apparatus according to claim 1 wherein each said inlet portion isoverlapped with another inlet portion for an adjacent slanted groove andhas a length sufficient to receive the wire.
 3. An apparatus accordingto claim 1 wherein the depth of each said groove is adapted to receivethe wire and said depth is gradually reduced toward said inlet portionso as to smoothly connect with another inlet portion for an adjacentslanted groove at the central portion of said roller.
 4. An apparatusaccording to claim 1 wherein the bottom of the inlet portion is plane orconvex so as to have a certain length.